Cooling system and method

Abstract

An energy storage module with one or more energy storage devices and a cooler on which the energy storage device is mounted in contact with the energy storage device. The cooler has one or more cooling fluid channels for circulating cooling fluid, the channels being in contact with a surface of the energy storage device, each cooling fluid channel being adapted to receive cooling fluid from a source of cooling fluid, extract heat from the energy storage device and return the cooling fluid to the source. At least a part of the cooling fluid channel includes a material having a melting point above 100° C.

The invention claimed is: 
     
       1. An energy storage module, the module comprising:
 a plurality of energy storage devices; and 
 a plurality of coolers, each cooler having one of the plurality of energy storage devices mounted thereon; 
 each cooler of the plurality of coolers comprises:
 a base panel that defines a pocket, a first inlet and a first outlet; 
 a cooler insert that partially encloses a plurality of cooling fluid channels for circulating cooling fluid, the cooler insert disposed within the pocket and including a second inlet and a second outlet; and 
 a plate in contact with the cooler insert and including a third inlet and a third outlet, the plate, the cooler insert, and the base panel cooperating to enclose the plurality of cooling fluid channels, the first inlet, the second inlet, and the third inlet cooperating to define a cooler inlet, and the first outlet, the second outlet, and the third outlet cooperating to define a cooler outlet; 
 
 an inlet manifold at least partially formed by the cooperation of the cooler inlets of each of the plurality of coolers; and 
 an outlet manifold at least partially formed by the cooperation of the cooler outlets of each of the plurality of coolers, wherein each of the cooling fluid channels is in direct contact with a surface of the energy storage device mounted thereto, each cooling fluid channel coupled to the inlet manifold to receive cooling fluid from a source of cooling fluid and coupled to the outlet manifold to return the cooling fluid to the source, and wherein the cooler insert, the base panel, and the plate are formed from a material having a melting point between 100° C. and 400° C. 
 
     
     
       2. The module according to  claim 1 , wherein the cooler is formed by additive manufacturing, welding, or lamination. 
     
     
       3. The module according to  claim 1 , wherein the cooling fluid channels have a circular or square cross section. 
     
     
       4. The module according to  claim 1 , wherein the cooling fluid channels have a wall thickness of no more 5 mm. 
     
     
       5. The module according to  claim 1 , wherein at least 30% of one surface of each energy storage device is in direct contact with the cooling fluid channels of the cooler to which it is mounted. 
     
     
       6. The module according to  claim 1 , wherein at least 75% of one surface of each energy storage device is in direct contact with the cooling fluid channels of the cooler to which it is mounted. 
     
     
       7. An energy storage module, the module comprising:
 one or more energy storage devices; and 
 for each energy storage device, a cooler on which the energy storage device is mounted, the cooler being in contact with the energy storage device; 
 wherein the cooler comprises one or more cooling fluid channels for circulating cooling fluid, the channels being in contact with a surface of the energy storage device, each cooling fluid channel being adapted to receive cooling fluid from a source of cooling fluid, extract heat from the energy storage device and return the cooling fluid to the source; 
 wherein the cooling fluid channels comprise a polymer material, polythene, polyamide, or thermal plastic; and 
 wherein at least a part of the cooling fluid channel comprises a material having a melting point within a melting point range, and wherein the cooling fluid channels further comprise one or more rupture sections having a melting point that is below the melting point range of the cooling fluid channels. 
 
     
     
       8. The module according to  claim 7 , wherein the melting point of the one or more rupture sections is between 130° C. and 180° C. 
     
     
       9. The module according to  claim 1 , wherein the energy storage device comprises one of an electrochemical cell, a battery cell, a fuel cell, a capacitor, ultracapacitor, or supercapacitor. 
     
     
       10. The module according to  claim 1 , wherein the energy storage device comprises a Li-ion, NiMH, or alkaline battery. 
     
     
       11. The module according to  claim 1 , wherein the cooling fluid comprises water or water glycol. 
     
     
       12. The module according to  claim 1 , wherein at least a part of the base panel, cooler insert, and the plate comprises a material having a melting point between 100° C. and 300° C. 
     
     
       13. The module according to  claim 1 , further comprising a plurality of flexible layers, each flexible layer disposed between and in direct contact with one of the plurality of energy storage devices and one of the plurality of coolers.